Multicore snowboard construction and production method

Abstract

A snowboard having a multicore construction comprising a plurality of layers, including at least two wood cores separated by an inner composite layer, and outer composite layers arranged between a wood core and the base or top sheet of the snowboard, respectively. Also, a production method for a multicore snowboard design.

1 . A snowboard having a multicore construction comprising:
 a plurality of layers including a base layer forming a gliding surface of the snowboard, a first outer composite layer, a second outer composite layer, at least one inner composite layer, at least two wood cores, and a top sheet layer;   wherein the base layer is arranged adjacent to the first outer composite layer;   the first outer composite layer is arranged between the base layer and one of the at least two wood cores;   the at least one inner composite layer is arranged between two of the at least two wood cores;   the second outer composite layer is arranged between the top sheet layer and one of the at least two wood cores; and   the top sheet layer is arranged adjacent to the second outer composite layer.   
     
     
         2 . The snowboard of  claim 1 , further comprising at least two inner composite layers and at least three wood cores, wherein each inner composite layer is arranged between two wood cores, and at least one wood core is arranged between two inner composite layers. 
     
     
         3 . The snowboard of  claim 1 , wherein the snowboard has exactly two wood cores. 
     
     
         4 . The snowboard of  claim 3 , wherein each of the two wood cores is approximately 2.5-3.5 mm thick. 
     
     
         5 . The snowboard of  claim 4 , wherein each of the two wood cores is approximately 3 mm thick. 
     
     
         6 . The snowboard of any of the preceding claims, wherein the wood cores together have a total thickness of approximately 5-7 mm. 
     
     
         7 . The snowboard of  claim 6 , wherein the total thickness of the wood cores is approximately 6 mm. 
     
     
         8 . The snowboard of any of the preceding claims, wherein the at least one inner composite layer comprises a sheet of carbon fiber composite. 
     
     
         9 . The snowboard of  claim 8 , wherein the sheet of carbon fiber composite is biaxial or triaxial woven. 
     
     
         10 . The snowboard of any of the preceding claims, wherein the first outer composite layer comprises a sheet of high modulus polypropylene composite. 
     
     
         11 . The snowboard of  claim 10 , wherein the sheet of high modulus polypropylene composite is biaxial or triaxial woven. 
     
     
         12 . The snowboard of any of the preceding claims, wherein the second outer composite layer comprises a sheet of high modulus polypropylene composite. 
     
     
         13 . The snowboard of  claim 12 , wherein the sheet of high modulus polypropylene composite is biaxial or triaxial woven. 
     
     
         14 . The snowboard of any of  claims 1  through  9 , wherein the first outer composite layer and the second outer composite layer each comprise a sheet of high modulus polypropylene composite. 
     
     
         15 . The snowboard of  claim 14 , wherein the sheet of high modulus polypropylene composite is biaxial or triaxial woven. 
     
     
         16 . A method for producing a snowboard having a multicore construction, comprising the steps of:
 arranging a base with steel edges in a mold;   arranging a first outer composite layer on the base in the mold;   arranging a first wood core on the first outer composite layer in the mold;   arranging an inner composite layer on the first wood core in the mold;   arranging a second wood core on the inner composite layer in the mold;   arranging a second outer composite layer on the second wood core in the mold;   arranging a top sheet on the second outer composite layer in the mold; and   placing the mold in a press for a period of time under pressure and temperature to shape and join components of the snowboard.   
     
     
         17 . The method of  claim 16 , further comprising the step of arranging a sidewall around sides of the first wood core, the inner composite layer, and the second wood core, prior to arranging the second outer composite layer on the second wood core in the mold. 
     
     
         18 . The method of  claim 17 , further comprising the step of applying a bonding agent to the sides of the first wood core, the inner composite layer, and the second wood core, prior to arranging the sidewall around the side of the first wood core, the inner composite layer, and the second wood core. 
     
     
         19 . The method of any of the preceding claims, further comprising the steps of:
 applying a bonding agent to the base prior to arranging the first outer composite layer on the base in the mold;   applying a bonding agent to the first outer composite layer prior to arranging the first wood core on the first outer composite layer in the mold;   applying a bonding agent to the first wood core prior to arranging the inner composite layer on the first wood core in the mold;   applying a bonding agent to the inner composite layer prior to arranging the second wood core on the inner composite layer in the mold;   applying a bonding agent to the second wood core prior to arranging the second outer composite layer on the second wood core in the mold; and   applying a bonding agent to the second outer composite layer prior to arranging the top sheet on the second composite layer in the mold.   
     
     
         20 . The method of  claim 18  or  19 , wherein epoxy is used for the bonding agent. 
     
     
         21 . The method of any of the preceding claims, further comprising the initial steps of:
 cutting two wood billets into a specified shape to form the first wood core and the second wood core;   planning each of the first and second wood cores to a specified thickness to accommodate the inner composite layer; and   cutting the inner composite layer to size for insertion between the first and second wood cores.   
     
     
         22 . The method of  claim 21 , further comprising the step of vertically laminating pieces of wood together to form each of the two wood billets. 
     
     
         23 . The method of  claim 21  or  22 , wherein a sidewall is added around the first and second wood cores prior to planning the first and second wood cores in order to correctly size the sidewall for later assembly. 
     
     
         24 . The method of any of the preceding claims, further comprising the step of affixing the steel edges to the base prior to arranging the base in the mold. 
     
     
         25 . The method of any of the preceding claims, further comprising the step of affixing rubber dampeners to the steel edges after arranging the base in the mold, but before arranging the first outer composite layer on the base in the mold. 
     
     
         26 . The method of any of the preceding claims, wherein the mold is an aluminum cassette mold. 
     
     
         27 . The method of any of the preceding claims, wherein the inner composite layer comprises a sheet of carbon fiber composite. 
     
     
         28 . The method of  claim 27 , wherein the sheet of carbon fiber composite is biaxial or triaxial woven. 
     
     
         29 . The method of any of the preceding claims, wherein the first outer composite layer and the second outer composite layer each comprise a sheet of high modulus polypropylene composite. 
     
     
         30 . The method of  claim 29 , wherein the sheet of high modulus polypropylene composite is biaxial or triaxial woven.